2002 Aston Martin V12 Vanquish Service & Repair Manual

V12 VANQUISH Workshop Manual Volume 1

Tickford Street, Newport Pagnell, Buckinghamshire, England MK16 9AN Telephone: (01908) 610620 Fax: (01908) 613708 Produced by the Technical Publications Department ASTON MARTIN LAGONDA LIMITED Issue 1 - June 2001 Part No. 1R12-43-10002

Introduction June 2001 1 General Information Workshop Manual Sections The AMV03 Workshop Manual is divided into 8 sections as follows 1 Engine 2. Fuel, Emission Control and Exhaust 3. Transmission 4. Suspension and Steering 5. Brakes, Wheels and Tyres 6. Electrics 7. Chassis and Body 8. Air Conditioning Procedure Numbering The workshop manual procedures are numbered using the parts list numbers as a key. The first two digits of a workshop manual procedure number are also the parts list number (e.g. 1.5.01 Sump Removal relates to PL 1.5 Oil Pump and Sump). Thus when carrying out a procedure, you can quickly locate the relevant parts illustration and spare parts list. To avoid excessive repetition, each procedure will be fully detailed once in its appropriate place in the manual. In any other location where this procedure is required, it will be referenced only by its title and its procedure number. Special Tools Where special service tools are required to perform an operation, the tool number is recorded at the point of use within the procedure. Consult the Special Service Tools catalogue for details of available tools. Location References References to the left, right, front or rear of the vehicle or of a component are always made as if sitting in the drivers seat facing forward. Any such references to assemblies removed from the vehicle are to the normal orientation of the assembly when fitted in the vehicle. Repairs and Replacements Where replacement parts are required, it is essential that only genuine Aston Martin parts are used. Your attention is drawn to the following points concerning repairs and the fitting of genuine Aston Martin parts and accessories: • Safety features embodied in the vehicle may be impaired if other than genuine Aston Martin parts are fitted. In certain territories, legislation prohibits the fitting of parts which are not produced to the manufacturers speci- fication. • Adhere to torque wrench settings given in this manual. • Locking devices, where specified, must be fitted. If the efficiency of a locking device is impaired during removal, it must be renewed. • The vehicle warranty may be invalidated by the fitting of other than genuine Aston Martin parts.

Introduction 2 June 2001 Safety Precautions All service workshops are a source of potential danger and repair work should only be performed by technically trained staff following the procedures in this manual. A safety conscious approach to the performance of all service procedures must be observed at all times. Statutory requirements governing all aspects of health and safety at work including directives for the proper use of materials and equipment must be implemented. The following contains a list of particular safety precautions which should be observed; it is not intended to be exhaustive. Air Conditioning System Do not break into the air conditioning refrigeration system until the refrigerant has been evacuated using the procedure in this manual. Do not disconnect any air conditioning refrigerant system pipes unless trained and instructed to do so. The refrigerant used can cause blindness if allowed to contact your eyes. Chemical Handling and Storage Chemicals used in the servicing of motor vehicles include acids, adhesives, antifreeze, brake fluids, coolants, grease, oil, paint, resin and solvents. Exposure to certain chemicals through direct contact or inhalation can be fatal. Potential hazards may also be present through the incorrect use, storage and handling of chemicals causing a fire risk. The following precautions should be observed. 1. Strictly adhere to handling and safety information found on containers and labels. 2. Do not store chemicals in unlabelled or incorrectly labelled containers. 3. Containers used for storing chemicals should not be left open; there is a risk of spilling, or evaporation of fumes which may be inﬂammable or toxic. 4. Do not mix chemicals unless instructed to do so following manufacturers guidelines. 5. Do not inhale chemical materials to determine identity, they may be toxic. 6. Do not use petrol, kerosene, diesel fuel, gas oil, thinners or solvents for washing skin. 7. Containers whose capacity is over 25 litres (5 gallons) require a bund wall in order to contain spillages. 8. Chemicals based on solvents such as paint should not be sprayed in a conﬁned space; work areas used for such operations should be well ventilated and fume extraction equipment should be utilised. 9. Ensure that adequate ventilation is provided when volatile de-greasing agents are being used. WARNING: Fume extraction equipment must be in operation when solvents are used e.g. trichloroethane, white spirit, SBP3, methylene chloride, perchlorethylene. WARNING: Do not smoke in the vicinity of volatile de-greasing agents. 10. Avoid splashing the skin, eyes and clothing. 11. Clean chemicals from the skin and clothing as soon as possible after soiling. 12. Wear protective clothing such as goggles, non porous gloves and apron when handling battery acid and other corrosive and toxic substances.

Introduction June 2001 3 Safety Precautions (continued) Electrical Equipment 1. Ensure that electrical equipment is in safe working order before use. 2. Inspect power leads of all mains electrical equipment for damage and security, and check that it is properly earthed. 3. Ensure that electrical equipment is protected by a fuse of the correct current rating. 4. Disconnect the battery before commencing repair operations to the electrical system, fuel system and engine or when working beneath the vehicle. Exhaust Fumes Engines should not be run in confined spaces, exhaust fumes contain harmful and toxic substances including car- bon monoxide which can prove fatal if inhaled. Engines must only be run where there is fume extraction equipment in operation or where there is adequate ventilation. Fire Precautions 1. Ensure that a suitable form of fire extinguisher is conveniently located near the work area. 2. Keep oils, solvents and combustible materials away from naked flames and other sources of ignition. 3. Ensure that NO SMOKING signs are posted around areas where combustible materials and vapour may be present and ensure that the warnings are strictly observed. 4. Ensure that dry sand is available to soak up any spillage of fuel or other flammable solutions. 5. Fume extraction equipment must be available and in full working order to remove combustible and toxic vapours. 6. All personnel should be aware of the fire drill procedures and precautions. Jacking and Lifting 1. The recommended procedures for lifting, jacking and towing are included later in this section and must be strictly observed to ensure personal safety. 2. Always use a vehicle hoist, ramp or pit for working beneath the car in preference to jacking. 3. Never rely on a jack to support a car independently, use axle stands or blocks carefully placed at the jacking points to provide rigid support. 4. When working beneath a vehicle, chock the wheels as well as applying the handbrake. 5. Ensure that the vehicle is standing on firm level ground before jacking or lifting. 6. Check any lifting equipment used has adequate capacity for the load being lifted and is in full working order.

Introduction 4 June 2001 Safety Precautions (continued) Tools and Equipment 1. Do not leave tools, equipment, spilt oil, etc. around or on the work area. 2. Ensure that tools and equipment used are in good condition; do not use damaged or defective tools or equipment. 3. Do not apply heat in an attempt to free stiff nuts or ﬁttings; as well as causing damage to protective coatings, the stray heat may damage electronic equipment, harnesses and brake lines. 4. Use the recommended service tool where instructed to do so. Used Engine Oil Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities should be provided. Health protection precautions: 1. Avoid prolonged and repeated contact with oils, particularly used engine oil. 2. Wear protective clothing, including impervious gloves where practicable. 3. Do not put oily rags in pockets. 4. Avoid contaminating clothes with oil. 5. Overalls must be cleaned regularly. Discard unwashable clothes and oil impregnated footwear. 6. First aid treatment should be obtained immediately for open cuts or wounds. 7. Use barrier creams, apply before each work period to help the removal of oil from the skin. 8. Wash with soap and water to ensure all oil is removed. Preparations containing lanolin replace the natural skin oils which have been removed. 9. Do not use petrol, kerosene, diesel fuel, gas oil, thinners or solvents for washing skin. 10. If skin disorders develop, obtain medical advice. 11. Where practicable, degrease components prior to handling. 12. Where there is a risk of eye contact, eye protection should be worn. In addition, an eye wash facility should be provided. Environmental Protection It is illegal to pour used oil on the ground, down sewers or drains, or into water courses. The burning of used engine oil in small space heaters or boilers is not recommended unless emission control equipment is fitted; in case of doubt, contact the Local Authority for advice on disposal facilities.

Introduction June 2001 5 Lifting and Jacking Safety Precautions 1. The recommended procedures for lifting, jacking and towing must be strictly observed to ensure personal safety. 2. Always use a vehicle hoist, ramp or pit for working beneath the car in preference to jacking. 3. Never rely on a jack to support a car independently, use axle stands or blocks carefully placed at the jacking points to provide rigid support. 4. When working beneath a vehicle, chock the wheels as well as applying the handbrake. 5. Ensure that the vehicle is standing on ﬁrm level ground before jacking or lifting. 6. Check that lifting equipment has adequate capacity for the load being lifted and is in full working order. Jacking Points The V12 Vanquish jacking points are at the posi- tions shown, where the vertical bulkheads join the horizontal floor pan. Always use a jack with a rubber contact pad. Avoid the use of jacks with sharp contact pads which would damage the floor pan Al- ways chock the opposite wheels as well as applying the handbrake when using the jack. To prevent body distortion, avoid single point or one side jacking with the tunnel shear panel removed Lifting The use of a workshop hoist is recommended for all operations where the vehicle must be raised. Follow the manufacturers instructions. If using an adjustable arm type, ensure that the lifting pads are correctly positioned at the four jacking points before lifting.

Introduction 6 June 2001 Workshop jack To avoid any danger of bodywork damage when using a hydraulic jack, the vehicle must only be lifted at the jacking points. Stands When carrying out work (other than a wheel change) which requires a wheel to be raised, a stand must be used, located at the jacking point, to provide a secure support for the vehicle. Front - one wheel Jack under the outer end of the lower arm using a suitable wooden block or rubber pad on the jack head. Rear - one wheel Locate the jack with a wooden block or rubber pad on its head, under the outer end of the lower wishbone at the wheel to be raised. Vehicle Recovery General The preferred method of vehicle recovery is by flat bed transporter. The front towing eye is primarily for emergency use when towing for short distances, e.g. removing the vehicle if it is causing an obstruction or winching the vehicle onto a flatbed transporter. If moving a V12 Vanquish in such a situation, fit the front towing eye to the bracket in the lower grille aperture. Caution: Take care to protect the paintwork when ﬁtting the towing eye. Make sure the towing eye is tight. Transporting If the vehicle is to be transported on a trailer or flat bed transporter, the handbrake must be applied and the wheels must be chocked. Suspended Towing Do NOT tow with sling-type equipment since damage to the bodywork will result. Take care when using 'spectacle frame' type towing equipment that the towing device is well clear of the front or rear apron. Body damage may occur if the vehicles pass over uneven road surfaces. Ensure that the recovery team follow these instructions:

Introduction June 2001 7 Front Suspended Tow 1.Switch on the ignition. 2.Pull both paddles simultaneousley twice to force the gearbox into Neutral. Switch of the ignition within three seconds. 3.Remove the ignition key from the ignition. 4. Raise the vehicle using a 'spectacle frame' type lifting device with a cradle positioned under each front wheel as shown below. Rear Suspended Tow 1.Set the steering in the ‘straight ahead’ position. Remove the ignition key from the ignition/steering lock. 2.Raise the vehicle using a 'spectacle frame' style lifting device where a cradle is positioned under each rear wheel as indicated below. Adhere to Towing Regulations In certain countries the registration number of the towing vehicle and an ON TOW sign or warning triangle must be displayed in a prominent position at the rear of the vehicle being towed. WARNING: When the engine is not running, the steering will no longer be power-assisted and the brake servo will become ineffective after a few applications of the brakes. Therefore be prepared for relatively heavy steering and the need for greatly increased brake pedal pressure. The vehicle may be towed short distances by another provided that a speed of 48 km/h (30 mph) is not exceeded. When being towed, the vehicles gear lever, or gear selector lever (automatic transmission), must be in Neutral or position N with the ignition key turned to position II to release the steering lock and to render the horn, indicators and brake lights operational.

Introduction 8 June 2001 Fluid Capacities Europe UK USA Engine sump (incl. filter) 9.5 litres (16.7 pints) (10.0 Qts) Engine sump (excl. filter) 8.5 litres (15.0 pints) (9.0 Qts) Engine cooling system 15 litres (26.4 pints) (16.5 Qts) Screen washer reservoir 2.0 litres (3.5 pints) (2.2 Qts) Gearbox & Cooler 4.17 litres (7.3 pints) (4.6 Qts) Final drive 2.0 litres (3.52 pints) (2.2 Qts) Fuel tank 80 litres (17.6 galls) (22.0 galls) Recommended Fluids Engine oil (Initial fill) Mobil 1 0w30 Engine coolant 60% water, 40% Havoline OAT Note: Do not mix OAT coolant with any glycol based anti-freeze. Gearbox oil Dexron III ASM Fluid FL CS Speed Final drive oil Mobil 1 80W-140 Brake fluid Castrol DOT4 Power steering fluid Esso Powersteering Fluid A/C refrigerant R134A (HFC134A) Engine Oil Do not mix Mobil 1 oil with any mineral oils.

2002 Aston Martin V12 Vanquish Service & Repair Manual

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